Strand lubrication

ABSTRACT

A strand being pulled through a conduit is automatically lubricated.

This patent application is a continuation-in-part and claims the benefitof the priority of U.S. patent application Ser. No. 09/991,418, filedNov. 15, 2001, which claims the benefit of the priority of U.S.provisional patent application 60/249,413, filed Nov. 16, 2000.

BACKGROUND

This invention relates to strand lubrication.

To make it easier to pull a strand or multiple strands (e.g., aninsulated electrical wire) through a conduit, the strand is oftenlubricated. One person typically applies the lubricant, for example,soap, to the strand by hand as one or more other people (depending onthe diameter and weight of the strand) withdraw the strand from a coilor other supply and feed it into the conduit. One or more people at theother end of the conduit pull on the strand while it is being lubricatedand fed.

The end of the conduit typically has an external thread. After the wireis pulled through the conduit, a standard cylindrical bushing is screwedonto the end of the conduit to protect the wire from damage that mightotherwise be caused by the sometimes-rough edge at the end of theconduit.

Various devices have been proposed to simplify the process oflubricating the strand while it is being pulled.

SUMMARY

In general, in one aspect, the invention features an apparatuscomprising a lubricator to dispense a lubricant onto a strand while thestrand is being pulled through a conduit, the lubricator being formed ofa plastic material and having embedded channels that carry the lubricantunder pressure from an inlet to outlets at which the lubricant isdispensed.

Implementations of the invention may include one or more of thefollowing features. The plastic includes glass-filled polypropylene. Thelubricator includes two plastic pieces. Ribs are formed on an outersurface of the lubricator.

In general, in another aspect, the invention features an apparatuscomprising a lubricator to dispense a lubricant onto a strand while thestrand is being pulled through a conduit, the lubricator configured toenable (a) a coupling of one end of the lubricator to an end of theconduit, and (b) a coupling of another end of the lubricator to aprotective bushing.

Implementations of the invention may include one or more of thefollowing features. The lubricator includes a thread on the one end toenable the coupling to the end of the conduit. The thread includes aninternal thread that mates with an external thread of the conduit. Thelubricator includes a thread on the other end to enable the coupling tobe mated to the protective bushing. The thread includes an externalthread that mates with an internal thread of the bushing. The lubricatorincludes an external thread on the other end that mates with an internalthread of the bushing and in which the internal thread on one end of thelubricator and the external thread on the other end of the lubricatorare of the same pitch and matching diameter. The lubricator includes twopieces that are separable to mount the assembly around the strand.

In general, in another aspect, the invention features a methodcomprising mounting a lubricator temporarily on an end of a conduitthrough which a strand is to be pulled, pulling the strand through abushing, the lubricator, and the conduit, unmounting the lubricator andremoving it from the strand without removing the bushing from thestrand, and mounting the bushing on the end of the conduit.

Implementations of the invention may include one or more of thefollowing features. The bushing is mounted on the lubricator beforepulling the strand. The bushing is unmounted from the lubricator beforemounting the bushing on the end of the conduit. The lubricator ismounted onto the threaded end of the conduit by threading or clamping.The bushing is mounted on the end of the conduit by threading. Thelubricator and the bushing are mounted on the end of the conduit usingthreads on the end of the conduit. The bushing is mounted on the end ofthe conduit without necessarily passing the bushing over a free end ofthe strand and along a length of the strand to reach the conduit.

In general, in another aspect, the invention features an apparatuscomprising a lubricator to apply a lubricant to a strand as it is pulledthrough a conduit, and a brush to prevent the lubricant from leaking outof the lubricator, the brush being removable from the lubricator forreplacement when the brush is worn.

Implementations of the invention may include one or more of thefollowing features. The brush includes bristles arranged in a ring, anend of each of the bristles being held in a ring-shaped ferrule. Thelubricator includes a receptacle into which the ring-shaped ferrule canbe inserted and removed for replacement. The lubricator includes agroove to mate with the ferrule. The brush is removable by sliding aportion of the brush with respect to a portion of the lubricator. Thebrush defines a chamber between the brush and the conduit when thelubricator is mounted on the conduit, and the lubricator includesoutlets configured to dispense lubricant into the chamber.

In general, in another aspect, the invention features an apparatuscomprising a lubricator to apply a lubricant to a strand as it is pulledthrough a conduit, the lubricator having (a) two separable pieces thatare joined to mount the lubricator around the strand and (b) a reservoirthat holds a supply of lubricant, the reservoir being split between thetwo separable pieces, and (c) a seal to seal the reservoir when the twopieces are joined, the seal comprising a silicone packing mounted in atleast one of the pieces.

Implementations of the invention may include one or more of thefollowing features. The reservoir includes a ring-shaped tube that isformed in a wall of each of the two separable pieces, the tube beingsplit when the pieces are not joined.

In general, in another aspect, the invention features an apparatuscomprising a set of lubricators, each of the lubricators to apply alubricant to a strand as it is pulled through a conduit, the lubricatorsbeing respectively configured for use with different sizes of conduit,and a holder having receptacles that are each sized to hold one of thelubricators of the set.

Implementations of the invention may include one or more of thefollowing features. There are at least two but fewer than sixlubricators in a set. A set includes a holder having receptacles thatare each sized to hold one of the lubricators within the set, all thelubricators within one set being a different size than any of thelubricators of another set. The holder includes an airtight containerthat is sealed to prevent the lubricant from drying out. Apparatuscomprising a container for a lubricator that is used to apply alubricant to a strand as it is pulled through a conduit, the containerincluding a receptacle that is configured to match a configuration of atleast part of the lubricator to hold the lubricator in place as thecontainer is moved, and a seal to prevent the lubricant from leakingoutside the container. The container includes a body and a lid and theseal is between the body and the lid.

In general, in another aspect, the invention features an apparatuscomprising an adaptor to adapt an end of a conduit to enable it toreceive a coupling of a lubricator when the end of the conduit is heldin a wall of a manhole, the adaptor including an annular body having oneend to insert into the end of the conduit and another end having acoupling to receive the coupling of the lubricator.

Implementations of the invention may include one or more of thefollowing features. The coupling of the adaptor includes threading. Theone end of the annular body is tapered. The adaptor includes two pieces.The two pieces include halves of a cylinder. The adaptor is formed ofplastic.

In general, in another aspect, the invention features an apparatuscomprising a pump to force a lubricant from a supply to a lubricator atwhich the lubricant is to be dispensed onto a strand that is beingpulled through a conduit, the pump being battery-powered.

Implementations of the invention may include one or more of thefollowing features. A battery-powered motor drives the pump. Apparatuscomprising a pump to force a viscous lubricant from a supply to alubricator at which the lubricant is to be dispensed onto a strand thatis being pulled through a conduit, the pump including a gear pump. Theapparatus of claim also comprising a battery-powered motor to drive thegear pump, the motor having different transmissions to vary the amountof lubricant applied to the strand. A foot switch turns the motor on oroff. The gear pump includes a pair of gears to force the lubricant froma reservoir to an outlet for a supply hose. A mechanism feeds lubricantfrom the supply to the reservoir. The mechanism includes an auger. Theauger is geared to the gear pump. The auger is driven to oversupply thereservoir relative to the amount of lubricant being pumped by the gearpump.

In general, in another aspect, the invention features an apparatuscomprising a pump to force a lubricant from a standard-sized bucket oflubricant to a lubricator at which the lubricant is to be dispensed ontoa strand that is being pulled through a conduit, the pump including aflange configured to mate with an opening of the bucket and support thepump above the bucket.

Implementations of the invention may include one or more of thefollowing features. An auger draws lubricant from the bucket, the augerbeing driven by a motor, the motor being mounted above the flange, theauger projecting below the flange. A follower plate has an aperturesized to accommodate the auger and to permit the follower plate to slideup and down along the auger. The follower plate has an outer edgeconfigured to match an inner-side wall of the bucket and configured toslide up and down the suction pipe around the auger.

In general, in another aspect, the invention features an apparatuscomprising a battery-powered pump to force a viscous lubricant from asupply to a lubricator at which the lubricant is to be dispensed onto astrand that is being pulled through a conduit, and a portable emergencybattery to power the pump, the portable emergency battery including anelectrical connector fitted to a housing of the battery to permit acable between the battery and the pump to be connected and disconnected.

Implementations of the invention may include one or more of thefollowing features. A foot switch controls the delivery of power fromthe battery to the pump.

In general, in another aspect, the invention features a methodcomprising mounting a lubricator on an end of a conduit, mounting abushing on another end of the lubricator, and pumping lubricant from asupply to the lubricator, pulling a strand through the lubricator andthrough the conduit, the lubricant being dispensed onto the strand fromthe lubricator during the pulling.

Implementations of the invention may include one or more of thefollowing features. The bushing is removed from the lubricator, thelubricator is removed from the conduit, and the bushing is mounted onthe conduit.

In general, in another aspect, the invention features a methodcomprising drawing a lubricant from a supply to a reservoir using anauger, forcing the lubricant from the reservoir between two meshinggears into a supply line, and delivering the lubricant through thesupply line to a lubricator to apply a lubricant to a strand as it ispulled through a conduit.

Implementations of the invention may include one or more of thefollowing features. The two meshing gears and the auger are driven froma single motor. The auger and the two meshing gears are driven atrelative speeds to cause the auger to oversupply the reservoir relativeto the rate at which the lubricant is forced from the reservoir into thesupply line.

In general, in another aspect, the invention features a methodcomprising pulling a strand from a supply of the strand through aconduit, at the supply end automatically lubricating the strand as itenters the conduit, and enabling a single person to control both thedelivery of the strand from the strand supply to the conduit and therate of delivery of lubricant from a supply of the lubricant.

Among the advantages of the invention are one or more of the following.Liquid soap or other lubricants (even very viscous lubricants) can beautomatically and evenly applied over the wire without the lubricanthaving to be applied from an electrician's hands. The use of such deviceby electrical, data, communications, and maintenance personnel who pullwire through conduits will permit a smoother pulling of the wire andless chance of damaging the wire. The use of the mechanical device alsoreduces manpower requirements and thus labor costs by reducing cleanuptime, material costs, and risk of damaging the wire.

Other advantages and features will become apparent from the followingdescription and from the claims.

DESCRIPTION

FIG. 1 is a top plan view of an automatic wire-lubricating device shownin an assembled condition.

FIG. 2 is a side elevational view of the device as seen along line 2-2of FIG. 1.

FIG. 3 is another side elevational view of the device as seen along line3-3 of FIG. 1.

FIG. 4 is a top plan view of a first component of the devicerepresenting approximately one half of the device.

FIG. 5 is a side elevational view of the first component of the deviceas seen along line 5-5 of FIG. 4.

FIG. 6 is another side elevational view of the first component of thedevice as seen along line 5-5 of FIG. 4.

FIG. 7 is a top plan view of a second component of the devicerepresenting approximately the other half of the device.

FIG. 8 is a side elevational view of the second component of the deviceas seen along line 8-8 of FIG. 7.

FIG. 9 is another side elevational view of the second component of thedevice as seen along line 9-9 of FIG. 7.

FIG. 10 is a three-dimensional view of another lubricator.

FIG. 11 is a cross-sectional view of the lubricator along line 11-11 ofFIG. 10.

FIGS. 12 and 13 are side-sectional views of the lubricator along lines12-12 and 13-13 of FIG. 10.

FIG. 14 is a top view of a dismantled brush.

FIG. 14A is a side view of the brush.

FIG. 15 is a three-dimensional view of a holder for the largest diameterlubricators.

FIG. 15A is a three-dimensional view of a holder for the medium diameterlubricators.

FIG. 16 is a three-dimensional view of a holder for the smallestdiameter lubricators.

FIG. 17 is a three-dimensional view of a pump.

FIG. 17A is a side view of the foot switch.

FIG. 17B is a top view of the foot switch.

FIG. 18 is a side-sectional view of the pump along line 18-18 of FIG.17.

FIGS. 19 and 20 are cross-sectional views of the pump along lines 19-19and 20-20 of FIG. 17.

FIGS. 20A and 20B are side views of the container.

FIG. 21 is a three-dimensional view of an adaptor.

FIGS. 22 and 23 are three-dimensional views of the two pieces of theadaptor.

FIGS. 24 and 24A are schematic views of the adaptor in use.

FIG. 25 is a side view of the battery and its electrical connector.

FIG. 26 is a three-dimensional view of a lubricator in use.

Referring to the drawings and particularly to FIGS. 1 to 3, there isillustrated an automatic wire lubricating device, generally designated10, in an assembled form. The device 10 basically includes first andsecond components 12, 14, each forming a body section 16, 18 ofgenerally arcuate and more particularly of semi-cylindricalconfiguration, and detachable fastening means 20 at the oppositeangularly displaced ends 16A, 16B and 18A, 18B of the respective body10, sections 16, 18 for releasably securing the first and secondcomponents 12, 14 together at flat end faces 16C, 16D and 18C, 18D toprovide the device 10 in the assembled condition of FIGS. 1 to 3. Theflat end faces 16C, 16D of the body section 16 lie in a common plane andlikewise the flat end faces 18C, 18D of the body section 18 lie in acommon plane, as clearly seen in FIGS. 4 and 7.

Referring also to FIGS. 4 to 9, there is illustrated the first component12 by itself in FIGS. 4 to 6 and the second component 14 by itself inFIGS. 7 to 9. The first component 12 of the device 10 has aquick-connect member 22 which fits, such as by being screwed, into apipe fitting 24 (such as ¼ inch in size) being attached, such as bybeing welded, onto an outer circumferential side 16C of the body section16 of the first component 12. The quick-connect member 22 can easily andquickly be attached to a soap line (not shown) coming from a pump (alsonot shown). The body sections 16, 18 of the respective first and secondcomponents 12, 14 together form an annular body 27 open at its axiallydisplaced opposite ends 27A, 27B with each body section 16, 18 definingone half of a continuous cylindrical interior reservoir 26 in theannular body 27, as seen in FIGS. 1-3, when the first and secondcomponents 12, 14 are fastened together. The continuous interiorreservoir 26 is in flow communication with the quick-connect member 22and pipe fitting 24 on the first component 12. The body sections 16, 18also have respective dispensing or applicator holes 28, 30 definedthrough the interior walls portions 16D, 18D thereof which provide flowcommunication between the interior reservoir 26 and a central opening 32formed through the annular body 27 of the device 10 by the first andsecond components 12, 14 thereof when the latter are fastened together.The annular body 27 being of cylindrical configuration has alongitudinal central axis A, as seen in FIG. 2, extending through thecentral opening 32 and between the opposite ends 27A, 27B of the annularbody 27.

The first and second components 12, 14 additionally have formed on theirbody sections 16, 18 at one of the axially displaced opposite ends 27Aof the annular body 27 respective halves of an internally threadedcylindrical clamping flange 34 which is concentric about thelongitudinal central axis A of the annular body 27. Also, the detachablefastening means 20 are disposed adjacent to the outer circumferentialsides 16E, 18E and the flat end faces 16C, 16D and 18C, 18D at therespective angularly displaced ends 16A, 16B and 18A, 18B of the bodysections 16, 18. The detachable fastening means 10 include pairs ofsleeves 36, 38 and pins 40. The sleeves 36, 38 are hollow for receivingthe respective pins 40. The sleeves 36 at the respective ends 16A, 16Bof the body section 16 and the sleeves 38 at the respective ends 18A,18B of the body section 18 are axially offset relative to one another,extend substantially equidistantly in opposite directions relative tothe continuous interior reservoir 26 in the annular body 27, andpartially project beyond the respective flat end faces 16C, 16D or 18C,18D, as seen in FIGS. 1 and 4-9. When the first and second components12, 14 are assembled together at the flat end faces 16C, 18C and 16D,18D of the body sections 16, 18, the sleeves 36, 38 at correspondingones of the ends 16A, 18A and 16B, 18B of the body sections 16, 18 aredisposed in pairs and aligned axially with one another along oppositeside axes B, C, which extend substantially in a parallel relationship tothe longitudinal central axis A of the annular body 27 and liesubstantially in a common plane formed by said flat end faces, as seenin FIGS. 1-3. The pins 40 are slidably inserted through the pairs ofaligned hollow sleeves 36, 38 so as to hold the two body sections 16, 18of the first and second components 12, 14 together. For taking the firstand second components 12, 14 apart, the pins 40 can be slidablywithdrawn from the pairs of aligned sleeves 36, 38 in the same reversedirection along the respective parallel side axes B, C of the alignedsleeves 36, 38.

Further, coupler pins 42, 44 of hollow construction and slightly arcuateshape are attached at the flat end faces 16C, 16D and 18C, 18D of theangularly displaced opposite ends 16A, 16B and 18A, 18B of the body 15sections 16, 18 of the first and second components 12, 14 so as toproject outwardly from the flat end faces 16C, 16D and 18C, 18D andprovide communication between the opposite ends of the halves of theinterior reservoir 26 defined by the body sections 16, 18. The hollowcoupler pins 42, 44 have O-rings 45 disposed around them and the couplerpins 42, 44 fit together so as to make a tight seal between the halvesof the interior reservoir 26 where the flat end faces 16C, 16D and 18C,18D of the body sections are placed flush together when the first andsecond components 12, 14 are fastened together.

The device 10 is connected to and held in place on a threaded end of aconduit (not shown) by attaching the two halves of the internallythreaded cylindrical clamping flange 34 about the threaded end of theconduit as explained above by inserting the pins 40 into the alignedsleeves 36, 38. When a pump feeds liquid soap through the quick connectmember 22 into the interior reservoir 26, the liquid soap travels 360degrees through the interior reservoir 26 around the device 10 andsquirts out through the interior dispensing or applicator holes 28, 30onto the wire being pulled through the central opening 32 of the device10 into the threaded end of the conduit.

The first and second components 12, 14 additionally have formed on theirbody sections 16, 18 at the other of the axially displaced opposite ends27B of the annular body 27 respective halves of an externally threadedcylindrical nipple 46 which is concentric about the longitudinal centralaxis A of the annular body 27. The nipple 46 allows the attachment of amember such as a bushing thereon to keep from scaring the wire or arubber grommet for ensuring a “no mess” application of soap on the wireduring a vertical pull thereof.

The actual physical size of the device 10 depends on the trade size ofthe conduit one is pulling wire through, resulting in a different sizedevice for each trade size of conduit. Also, it should be understoodthat the device 10 can be manufactured by various suitable conventionalmethods using various suitable conventional materials and having variousdifferent configurations.

In summary, the automatic wire-lubricating device 10 is a double pinclamping device that clamps over all trade size conduits and has a smallmale adapter or quick-connect 22 that connects to either a manual orelectrical pump for supplying liquid soap into the device 10 and has aplurality of interior holes 28, 30, such as four in number, from whichliquid soap is dispensed evenly and completely over the wire so as tolubricate the wire as it is pulled through the central opening 32 of thedevice 10. The advantages of the device 10 are: (1) mess freeapplication; (2) less cleanup; (3) less manpower required; (4) lessexpense; and (5) more consistent job of lubricating the wire beingpulled.

As shown in FIG. 10, in another example of a lubricator 110, two ribbed,semi-cylindrical pieces 116 and 118 can be fastened together (andunfastened) by detachable pins 120, 121 to mount (and remove) thelubricator, made of a material such as plastic, onto an externallythreaded end 123 of a conduit 125.

By conduit, we mean in the broadest sense any kind of pipe, tube,sleeve, or other elongated element that has been fabricated in anymanner using any continuous or discontinuous material and that has achannel or lumen within which one or more strands extend. One specificexample of a conduit is a metal pipe used to carry electrical wires in abuilding. By strand we mean, in the broadest sense, a wire, cable,thread, braid, fiber, or other elongated element that has beenfabricated in any manner using any material and may extend within aconduit alone or together with multiple strands equal in length. Wesometimes use strand to refer to more than one strand.

The lubricator bears an internal thread 112 and an external thread 114.The internal thread and the external thread may be of the same pitch anddiameter (which is useful in connection with attachment of a bushingdescribed later) or may be of different pitches and diameters. Thethreads are shown in the figure as being aligned on a common axis, butthey could also be aligned on different axes that are either parallel toone another or at an angle to one another.

The internal thread 112 enables the mating of the lubricator 110 withthe externally threaded end 123 of the conduit 125. The external thread114 enables the attachment of a conventional (or special)internally-threaded 117 protective bushing 115 to the lubricator 110.The bushing has a leading edge 103 that is, for example, smooth androunded to protect a strand against abrasion and damage when it ispulled through the bushing. A hose (not shown) that carries a lubricantpumped from a supply (not shown) attaches to a pipe-fitting, using aquick-connect coupling (not shown). The fitting and coupling can be ofthe kind shown and described in FIGS. 1, 2, and 3. Lubricant that ispumped from the supply into the lubricator exits through dispensingholes 128 (only one is shown in FIG. 10) that open on an interiorsurface of the lubricator 110.

FIG. 11 shows a cross-section of the lubricator at 11-11 of FIG. 10.When the semi-cylindrical pieces 116, 118 are closed together, they maybe fastened together by pins 120, 121 placed through the sleeves 124,125. Within each of the pieces 116 and 118 and at locations near thesleeves 124, 125 are, in this instance, rings of silicon packing 134,135, lying at the bottom of the grooves 1350, 1360, which assure a tightseal of the mating ends of annular tubes 137, 139 to form an interiorreservoir that carries lubricant from the pipe fitting to the dispensingholes 128 (FIG. 10).

As shown in FIGS. 12 and 13, the lubricator 110 includes a removable,annular brush 144 shown in detail in FIG. 14 that is used to preventleakage of the lubricant from the lubricator as the strand is beinglubricated. When the amount of the lubricant fed from the dispensingholes onto the strand is more than is needed to lubricate the strand,the excess is retained in the chamber that is between the brush bristlesand the end of the conduit.

The brush includes two semi-circular half-brushes 139, 141, each havinga metal semi-circular ring 146, 148 (FIG. 14) that is held within acorresponding semi-circular groove 136, 138 that is formed in theinterior wall 150, 152 of each piece 116, 118 of the lubricator 110. Thesemi-circular grooves are offset from one another along the axis of thelubricator so that when the two pieces of the lubricator are closed tomount the lubricator on the conduit, the bristles of the two halves willnot engage one another in a way that makes closing the two pieces moredifficult.

The semi-circular rings of the brush are configured to slide within thegrooves to permit the halves of the brush 146, 148 (FIG. 14) to beremoved for replacement by sliding. The replacement half-brushes 146,148 are then fit snuggly in place after having been slid onto thesemi-circular grooves 150, 138. Smaller versions (for example, smallerthan 1½ inches in diameter) of the lubricator do not require a brushbecause they do not tend to leak lubricant. Those smaller lubricatorsresemble that of FIGS. 12 and 13, except for the absence of a groove forattaching a brush. Retaining clips 710, 720 hold the brush in place whenthe lubricator is separated into halves.

As FIGS. 14 and 14A show, each of the half brushes is semi-circular. Oneend of each of the bristles 160 is held in a the semi-circular ferrule146 (bristles are not shown with the ferrule 148), which has aconfiguration that fits the lubricator groove 136. The other end of eachof the bristles projects toward the axis of the ring. There are enoughbristles in the brush to assure that the lubricant has difficultyleaking through the brush.

Because conduits vary widely in diameter, it is useful to have a varietyof sizes of lubricators available. The lubricators of different sizescan be provided in sets. A set could include all of a wide range ofsizes of lubricators (for example, twelve different lubricators rangingin internal diameter from ½ inch to 6 inches) or the lubricators can beorganized in smaller sets that relate to specific size-ranges ofconduits, for example, a set for smaller diameter conduits and a set forlarger diameter conduits. The lubricators of a set can be housed in aholder such as the holders 170, 171, 172 for each of the sets 174, 176,178 of lubricators 161-168, 910-913, as shown in FIGS. 15, 15A, and 16.The holder provides a convenient way to transport and store the set andprevents lubricant on the lubricators from either drying out or leakingout of the holder.

Each of the holders 170, 171, 172 is a closable container that includesa body 173, a lid 175, and a seal 177 between the body and lid. Thelubricators 161-168, 910-913 come in small 178 (lubricators withdiameters of ½, ¾, 1, 1¼, 1½, and 2 inches), medium 176 (with diametersof 2½, 3, 3½, and 4 inches), and large 174 (with diameters of 5 and 6inches) sets, with each set containing at least two lubricators. Eachlubricator 161-168, 910-913 sits in a separate receptacle 181-188,920-923. When the lid of a holder is closed on the body and latched, theseals make the holder 170, 171, 172 airtight.

Each set contains at most six lubricators. A set includes a holder withappropriately sized receptacles each configured for one of thelubricators within the set; all the lubricators within one set are of adifferent size than all the lubricators within another.

Similarly, the receptacle for each lubricator is contoured to match atleast a part of the lubricator to keep the lubricator in its place.

All of the lubricators of a set (and of all sets) share a common sizeand type of pipe-fitting and quick-connect coupling to accommodate onesize of hose that extends from the pump.

As shown in FIG. 17, a pump 280 transfers the lubricant from a supply tothe lubricator through a connecting hose (not shown in FIG. 17, 326 inFIG. 18). Using an auger 290 rotating within an auger tube (not shown inFIG. 17, 309 in FIG. 18), the pump forces a viscous lubricant from astandard bucket (not shown in FIG. 17, 328 in FIG. 18) in which thesupply is held to an internal reservoir (hidden in FIG. 17) of the pumpwhere the lubricant is held. The lubricant could be a viscous ornon-viscous material, for example, a soap, a detergent, an oil, or agrease. The assembly also contains two meshing gears that form a gearpump. The gear pump forces the lubricant from the reservoir 138 into ahose (not shown in FIG. 17; 326 in FIG. 18), which then carries thelubricant to the lubricator. The auger 290 and the meshing gears (hiddenin FIG. 17) of the pump are driven by a commercially available motor(not shown; available from Black & Decker in Kansas City, Mo.). The pumpoperator turns the motor on or off using a foot switch (not shown inFIG. 17, 332 in FIGS. 17A, 17B, and 26; also available from LinemasterCorporation in Woodstock, Conn.). The speed of the motor is controlledby a three-speed transmission, which controls the amount of lubricantdispensed onto the strand. The motor is powered by a battery (not shownin FIG. 17, 400 in FIG. 25).

The battery may be a standard 12-Volt battery held in a commerciallyavailable portable emergency housing (for example, available from TeamProducts International in Parsippany, N.J.). An electrical connector 286(FIGS. 20A, 20B and 25) may be added to the housing of the battery topermit quick, reliable, repeated connection or disconnection of a cable284 (FIGS. 20A, 20B, and 25) between the battery 400 (FIG. 25) and thepump 280.

As shown in FIG. 18, within the reservoir 291 of the pump 280, the upperend of the shaft of the auger is housed together with the meshing gears294, 296 of the gear pump so that when the lubricant is drawn into thereservoir by the auger, the lubricant will be picked up by the meshinggears and pumped to the supply line 326. As shown in FIG. 19, above thereservoir, one of the meshing gears is driven by a drive gear 302, whichin turn is driven by an intermediate gear 303, which in turn is drivenby an auger gear 298 that is connected to the upper end of the augershaft 306. The upper end of the auger shaft is keyed 308 to the augergear. The keyed upper end of the auger shaft (at a location above theauger gear) is driven by the motor. The gear ratio effected by the augergear, the intermediate gear, and the drive gear is arranged to tend toforce an oversupply of lubricant into the reservoir 426 relative to theflow of the lubricant from the reservoir to the supply line.

The auger 290 has a screw portion 310 arranged along its length, and atubular sleeve 309 around the screw that defines a channel from the tipof the auger 311 to the top of the auger 312. During operation, as theauger is driven by the motor, lubricant is drawn up from the supplybucket into the reservoir 426. The meshing gears 294, 296 force thelubricant out of the reservoir 426 and into the connecting hose 326, tobe dispensed by the lubricator (for example, the lubricator shown inFIG. 10) onto a strand.

The block 312 that contains the reservoir is bolted to a flange 314 thatserves as a substitute lid for the supply bucket. The flange 314 isround and has a peripheral wall 315 that is sized and configured to matewith the opening of the bucket and supports the pump 280 that sits atopit. Inside the bucket, a follower plate 316, with a hole 318 slightlylarger in diameter than the diameter of the auger tube can slide freelydown the auger tube as the lubricant is pumped out. The follower plate316 has a steel center disk 320 and a flexible outer ring 322 that wipesthe inner wall 324 of the bucket as the follower plate descends. As thelubricant is pumped out of the bucket, the follower plate descends bygravity, wiping the inner wall clean and causing the remaining supply oflubricant to lie in a compact cylindrical mass on the bottom of thebucket. This arrangement assures that the auger can pump effectivelyuntil all of the lubricant is removed.

The auger may be made of steel or a polymeric material.

FIGS. 20A and 20B show side views of two containers 700, 701 that holdthe battery 400, pump 280, and either a one-gallon (FIG. 20A) or afive-gallon (FIG. 20B) supply bucket 328, 329. The battery 400 isconnected to the pump 280 by a cable 284 attached to an electricalconnector 286. The pump 280, in turn, is connected to the lubricator(not shown) by a hose 326. For the one-gallon supply bucket 328 in FIG.20A, both the pump 280 and supply bucket 328 sit within the samecontainer 700 as the battery 400. A handle 750 allows for the container700 to be carried by hand. For the five-gallon supply bucket 329 in FIG.20B, the battery 400 sits in a separate compartment 760 from the pump280 and supply bucket 329. This container 701 is transported on casters761. Both are metal containers 700, 701 that prevent leakage oflubricant when the assembly is transported.

In some situations, the near end of the conduit lacks threading, such aswhen the conduit is held in a wall 502 of a manhole 504 with the end 506of the conduit held near the inside of wall 508, as illustrated in FIGS.24 and 24A. In such a situation, an adaptor 516 may be mounted on thenear end of the conduit to provide a threaded end onto which thelubricator 110 may be screwed. The adaptor 516 has two semi-cylindricalhalves 530, 550 that, when mated, form an annular body 516. The smoothend 518 of the adaptor slides into the conduit while the threaded end520 receives the lubricator 110. The outer wall 522 of the adaptor istapered so that the adaptor slides easily into conduits of slightlydifferent inner wall diameters and can be jammed into the conduit tohold it securely during the pulling operation. Once lubrication iscompleted, the lubricator 110 is removed from the adaptor 510 bydetaching the semi-cylindrical halves of the coupling 530, 550;similarly, the adaptor 510 slides out from the conduit 580 and theadaptor's semi-cylindrical halves 530, 550 are subsequently separatedfrom each other.

As shown in FIG. 22, a piece 530 that forms half of the manhole adapterhas a semi-cylindrical upper section 532, which includes externalthreads 534 that are sized to accept the internal threads of one end ofa lubricator (for example, the lubricator shown in FIG. 10), and asemi-cylindrical lower section 536, which includes a tapered wall 538.The diameter of the lower section 536 enables it to fit with a conduit(not shown) that is mounted within a wall of a manhole. The taper isrepresented by an offset 540 of the outer surface of section 540relative to an imaginary line 544 that is a line with the central axis(not indicated) of the adaptor. Two notches 546, 548 in the edges ofpiece 530 are configured to mate with two plugs 566, 568 of the otherhalf of the adaptor (shown in FIG. 23) to form the complete adaptor(shown in FIG. 21) and to prevent relative motion of the receptive twohalves of the adaptor along the central axis.

Likewise, as shown in FIG. 23, a piece 550 that forms the other half ofthe manhole adaptor also has a semi-cylindrical upper section 552 andhas essentially the same configuration as the piece 530 shown in FIG.22, except that it has two plugs 566, 568 configured to mate with twonotches 546, 548 of the other half of the adaptor (shown in FIG. 22) toform the complete adaptor (shown in FIG. 21) and to prevent relativemotion of the receptive two halves of the adaptor along the centralaxis.

FIG. 25 shows a standard 12-Volt emergency battery 400 with itselectrical connector 286 and an electrical connecting cable 284; in thisillustration, the battery is not attached to the pump's motor.

As shown in FIG. 26, in use, the battery 400 is electrically connectedby the cable to the motor within the pump 280. A lubricator 110 isattached to a conduit 402, through which a strand 404 is being pulled. Ahose 326 connects the lubricator 110 to the pump 280 that sits atop astandard supply bucket 328 filled with lubricant. A foot switch 332controls the connection of the battery 400 to the motor, while athree-speed transmission controls the motor's speed to regulate the rateat which lubricant is pumped onto the strand 404.

As shown in FIG. 26, in use, the electrician brings to the job site thecontainer 800 that holds the bucket of lubricant and the pump and alsobrings the holder 810 that contains the lubricator to be used on thejob. Assume that an insulated wire 404 from a supply 412 is to be pulledfrom a supply spool 414 at a near end 416 of the conduit through a steelconduit 418 to the other end 420. The electrician takes the lubricatorthat is of the correct size for the conduit from the holder and mountsit on the end of the conduit either by screwing it onto the externalthreads or by removing one of the pins, opening the lubricator and thenclosing it over the end of the conduit and replacing the pin. If astandard bushing 422 has not previously been mounted on the other end ofthe lubricator, the electrician screws it onto the threads.

From the other end of the conduit a stiff wire is forced through theconduit to the near end. A free end of the wire to be pulled is thenattached to the free end of the stiff wire. If not already done, theelectrician attaches the foot switch to the motor of the pump and placesit in a convenient location. If not already done, he mounts the pump onthe top of the bucket of lubricant. He connects one end of a supply lineto the outlet of the pump and the other end of the supply line to thequick-release coupling of the pump. He connects the battery connector tothe pump using an electrical cable.

The stiff wire at the far end of the conduit is pulled to begin to pullthe insulated wire into the near end of the conduit. The electriciansteps on the foot switch to begin to force lubricant into the supply,into the reservoir in the lubricator, and from the reservoir into thechamber that lies between the brushes and the near end of the conduit.With the lubricant flowing, the electrician draws a supply of theinsulated wire from the spool as the stiff wire is pulled from the farend of the conduit. As the insulated wire passes through the conduit,the outer wall of the wire is automatically coated with lubricant fromthe supply that is built up in the chamber next to the brushes. Theelectrician at the same time can both feed wire from the spool andcontrol the speed of lubricant pumping using the foot switch to controlthe motor speed. If the rate of pumping is too high, lubricant may beginto be forced through the brush. The electrician could then reduce themotor speed. If the rate of pumping is too low, the wire will not feedeasily through the conduit, and the electrician can increase the rate ofpumping.

The gear pump is capable of very high pumping pressures (e.g., as highas 2500 psi). In combination with the auger approach of drawinglubricant from the bucket, this makes it possible to successfully pumpextremely viscous lubricants from the bucket and feed them into thelubricator.

When the end of the insulated wire has been pulled through the conduitand extends as far as needed from the far end of the conduit, theelectrician can stop the pump. The next step is to unscrew the bushingfrom the end of the lubricator. Then the lubricator is removed from theend of the conduit by removing one of the pins and opening the twohalves. Once the lubricator has been removed, the bushing, which has theinsulated wire running through it and has been held near the end of theconduit, is screwed onto the end of the conduit to complete thewire-pulling job.

The lubricator can then be returned to the holder without cleaning it,and the pump with bucket and the battery can be returned to the carrieralso without cleaning them.

With use, the half-brushes may become worn or damaged and need to bereplaced. Replacement is done simply by sliding the metal ring ferrulealong the groove in which it is held until it is free and then reversingthat step using the replacement brush.

Although particular implementations have been described above, otherimplementations are also within the scope of the following claims.

For example, the lubricator can be mounted on the conduit and thebushing can be mounted on the lubricator using mechanisms other thanthreads.

1. An apparatus comprising a lubricator to dispense a lubricant onto astrand while the strand is being pulled through a conduit, thelubricator being formed of a plastic material and having embeddedchannels that carry the lubricant under pressure from an inlet tooutlets at which the lubricant is dispensed.
 2. The apparatus of claim 1in which the plastic comprises glass-filled polypropylene.
 3. Theapparatus of claim 1 in which the lubricator comprises two plasticpieces.
 4. The apparatus of claim 1 also including ribs formed on anouter surface of the lubricator. 5-18. (canceled)
 19. An apparatuscomprising a lubricator to apply a lubricant to a strand as it is pulledthrough a conduit, and a brush to prevent the lubricant from leaking outof the lubricator, the brush being removable from the lubricator forreplacement when the brush is worn.
 20. The apparatus of claim 19 inwhich the brush includes bristles arranged in a ring, an end of each ofthe bristles being held in a ring-shaped ferrule.
 21. The apparatus ofclaim 20 in which the lubricator includes a receptacle into which thering-shaped ferrule can be inserted and removed for replacement.
 22. Theapparatus of claim 21 in which the lubricator includes a groove to matewith the ferrule.
 23. The apparatus of claim 19 in which the brush isremovable by sliding a portion of the brush with respect to a portion ofthe lubricator.
 24. The apparatus of claim 19 in which the brush definesa chamber between the brush and the conduit when the lubricator ismounted on the conduit, and the lubricant includes outlets configured todispense lubricant into the chamber. 25-26. (canceled)
 27. An apparatuscomprising a set of lubricators, each of the lubricators to apply alubricant to a strand as it is pulled through a conduit, the lubricatorsbeing respectively configured for use with different sizes of conduit,and a holder having receptacles that are each sized to hold one of thelubricators of the set.
 28. The apparatus of claim 27 in which there arefewer than six lubricators in the set.
 29. The apparatus of claim 27 inwhich the set includes at least two subsets of the lubricators, and alsoincluding a second holder having receptacles that are each sized to holdone of the lubricators of one of the subsets, the lubricators of one ofthe subsets all being larger than any of the lubricators of the other ofthe subsets.
 30. The apparatus of claim 27 in which the holder comprisesan airtight container that is sealed to prevent the lubricant fromdrying out.
 31. Apparatus comprising a container for a lubricator thatis used to apply a lubricant to a strand as it is pulled through aconduit, the container including a receptacle that is configured tomatch a configuration of at least part of the lubricator to hold thelubricator in place as the container is moved, and a seal to prevent thelubricant from leaking outside the container.
 32. The apparatus of claim21 in which the container includes a body and a lid and the seal isbetween the body and the lid. 33-60. (canceled)